Process monitoring with versatile cameras
Camera surveillance is a well-known phenomenon.
Security cameras are used as a measure against crime: guarding people and goods.
But just as often, these security cameras are used for completely different applications where they are at least as useful.
In this article, you will learn how cameras can monitor processes in a production environment. Security camera footage is displayed 24/7 on monitors or recorded on hard drives.
In the event of an incident, the recorded images can be used to analyse the incident afterwards and for criminal or legal purposes.
Security cameras have become increasingly powerful and versatile in recent years, making them suitable for a multitude of applications.
Smart cameras, for example, can take counts and track people and objects.
The information from these systems can be very valuable for security but also for business operations.
A camera system can therefore play an important role in industrial processes, such as conveyor belts, production processes and the processing and storage of goods.
A temporary set-up can keep an eye on a new production process, while a permanent set-up provides continuous insight into the process.
Quality assurance in production environment
In a modern production company, processes are sometimes so fast that cameras are used for quality control.
Special software can be used to check the shape and colour of products.
By linking the camera system to the process, it can be stopped to manually remove the erroneous products or have them automatically removed from the production process.
This fast and accurate detection is possible thanks to the high refresh rate and light-sensitive image sensors of today’s cameras.
License plate recognition for barcodes
Speed also plays an important role in license plate registration.
The Optical Character Recognition (OCR) of the license plate registration software is therefore also suitable for reading barcodes on packages and products.
Conversely, an existing barcode scanner can be linked to the Video Management System to create ‘bookmarks’, so that the recorded images of specific packages/products can be found easily and quickly.
With the current generation of light-sensitive megapixel cameras, the processes can be monitored easily and in detail even in dark situations.
The live camera images provide real-time insight into the process progress, while the recorded images can help you with the analysis of incidents afterwards; When did the product fall off the assembly line and why?
Video Content Analysis
A camera system with Video Content Analysis offers even more added value.
The proven algorithm ‘cross line’ detection can be used to signal falling products from a conveyor belt, ‘movement in zone’ detection to signal objects that end up in a place where they do not belong and ‘counting’ to count products.
Of course, these algorithms can be used not only for objects, but also for people.
When we link this information to other security or process monitoring systems, we can identify suspicious or dangerous situations.
Overload Signaling
Manufacturers nowadays combine the power of thermal cameras with the properties of optical cameras in so-called combi cameras: an optical and a thermal sensor in one housing.
Such a camera can be used, among other things, to measure abnormal temperature increases very accurately, for example as a result of overloading machines or electrical installations.
The optical lens offers the possibility to quickly assess the situation from a distance with the help of ordinary camera images.
These cameras are used by waste processors.
Fires regularly occur there as a result of scalding.
Through the use of thermal and combi cameras, heating can be detected very quickly and accurately; even before a fire actually starts.
Smoke detectors are usually not an option there, as they are too slow and the space is too large.
Safety and security function
In industrial environments, a camera system can of course also have a safety and/or security function.
To detect employees who are in a hazardous area of the production process, for example.
And at night, another profile in the camera can be activated (automatically by a time setting), so that the function of process observation turns into that of security.
Then the camera system will be used to identify unauthorized or malicious persons in the building or on the site.
The entire production process in the huge complex of the ARN waste-to-energy plant is monitored and controlled 24 hours a day from a control room.
HD cameras supervise the (logistical) process at Banken Champignons.
The Coatinc Company has increased the safety for its staff by deploying cameras and microphones in the galvanizing hall during the most risky moment of the galvanizing process.